Vehicle seat with improved craftsmanship

ABSTRACT

A process for improving vehicle seat craftsmanship by camouflaging a receiving surface on a predetermined vehicle component (e.g., a foam seat cushion) is described. The camouflaging conceals the vehicle component from observation. One example of the process includes designating a receiving surface area on the vehicle component and providing a covering material having an opaque characteristic. The covering material includes an opaque dye that bonds with the polyurethane foam that is poured into a mold with deionized water for solidification. Another example of the process further includes spraying the covering material according to a surface of the mold cavity which corresponds to the designated receiving surface area on the vehicle component.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application claims the benefit of U.S. Provisional PatentApplication No. 60/788,308 (“Vehicle Seat with Improved Craftsmanship”)filed Mar. 31, 2006, which is hereby incorporated by reference it itsentirety.

BACKGROUND

The application generally relates to a vehicle component assembly and toa process for improving vehicle craftsmanship. The application relatesmore specifically to nonionic polymeric colorant covering materials forspray application to vehicle components, including foam vehiclecomponents, and an associated process for improving vehicle seatcraftsmanship.

Vehicle craftsmanship directly influences consumer purchasing decisions.Motor vehicles include a substantial number of assembled componentshaving multiple design considerations. The same holds true for a vehicleseat. In the vehicle seat, there are seat portions having foam such asthe vehicle seat back and seat cushion. The foam typically has a whiteor substantially yellow colored tone; however, vehicle interiors arecommonly gray, black or beige in color. When the light colored foam isvisible, it contrasts with darker toned portions of the vehicleinterior; the foam can easily be noticed and draw unwanted attention tothat area of the vehicle interior.

One potential solution proposed by some foam manufacturers is to includea dye within the foam mixture. The appearance of the colored foam isless noticeable (or at least compliments the other components of thevehicle). While providing colored foam makes the foam less noticeable,it may be costly and potentially complicates the overall productionprocess.

Marking of the foam has been utilized to color code areas of the foam soas to identify preferred assembly positions. However, the color-codingis typically applied to small areas and in a manner to be identified notconcealed. For example, a green or red circle may be provided on thesurface of the foam to indicate an upward position of mounting a foamseat cushion with respect to the seat frame. Likewise a red mark on thesurface of a foam seat cushion may indicate the corresponding vehicle—ina multi-vehicle assembly line—for the seat cushion. Inapposite tocamouflaging, flagging a surface of the foam serves to identify andbring attention to certain sections of the vehicle components.

Another method of covering foam pieces is to provide fabric that isapplied to the molding cavity of the foam prior to molding the foam. Thefabric is placed in the mold cavity and the polyurethane mixture isdispensed therein. Such additional parts can prove to be a costlyaddition to the price of the vehicle component.

Another method of concealing certain areas of vehicle components is toapply a plastic covering material or plastic insert covering theoffending white area of the foam from vehicle occupants as a finishingstep before shipment. Again, this may have significant cost implicationson the vehicle component due to the need for additional parts.

Despite known methods for marking vehicle components to simplify themanufacturing process, craftsmanship issues persist regarding thevisibility of off-colored vehicle components.

SUMMARY

One exemplary embodiment a process for improving vehicle seatcraftsmanship by camouflaging a receiving surface on a vehiclecomponent, the camouflaging thereby concealing the receiving surface ofthe vehicle component. The process includes designating a receivingsurface area on the vehicle component, and providing a covering materialhaving an opaque characteristic. The covering material includesdeionized water, an opaque dye, and silicone material. The process alsoincludes spraying the covering material in a mold cavity at a surface ofthe mold cavity corresponding to the designated receiving surface areaon the vehicle component until the covering material completely coversthe surface defined on the mold cavity.

Another exemplary embodiment relates to a process of making a coveringmaterial for camouflaging a vehicle component upon application, thecamouflaging thereby concealing the vehicle component from observationand improving overall vehicle craftsmanship. The process includesproviding a silicone material, adding a deionized water-based solutionto the silicone material, adding an opaque dye to the deionizedwater-based solution and the silicone material, mixing the siliconematerial, water-based solution and opaque dye in a blend tank, andheating the covering material to a predetermined temperature.

Another exemplary embodiment relates to a covering material forcamouflaging a vehicle component upon application, the camouflagingthereby giving the appearance of concealing the vehicle component fromvehicle passengers. The covering material comprises a silicone material,a deionized water-based solution, and an opaque dye. The coveringmaterial is configured to be combined with a polyurethane solutionforming a foam seat member upon emulsification.

Another exemplary embodiment relates to a process for improving vehicleseat craftsmanship by camouflaging a plurality of receiving surfaces ona vehicle component, the camouflaging thereby concealing the pluralityof receiving surfaces on the vehicle component. The process includesdesignating the plurality of receiving surfaces on the vehiclecomponent, providing a covering material having an opaquecharacteristic, and providing a mold cavity. The mold cavity defines aplurality of corresponding receiving surfaces, each correspondingreceiving surface assigned to one of the plurality of receiving surfaceson the vehicle component. The process further includes providing a sprayapparatus, applying the covering material to the corresponding receivingsurfaces of the mold cavity, and pouring a polyurethane mixture into themold cavity for solidification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle having a vehicle seat thereinaccording to an exemplary embodiment.

FIG. 2 is a perspective view of a mold cavity according to one exemplaryembodiment.

FIG. 3 is a perspective view of the mold cavity of FIG. 2 with coveringmaterial applied thereto according to one exemplary embodiment.

FIG. 4 is a perspective view of foam with covering material appliedthereto according to one exemplary embodiment.

FIG. 5 is a perspective view of a vehicle component with coveringmaterial applied thereto according to one exemplary embodiment.

FIG. 6 is a perspective view of a vehicle component with coveringmaterial applied thereto according to one exemplary embodiment.

FIG. 7 is a perspective view of a vehicle component with coveringmaterials having different water levels applied thereto according to oneexemplary embodiment.

FIGS. 8 a-d are side and perspective views of a spray apparatus and amold cavity according to one exemplary embodiment.

FIGS. 9 a-b are perspective views of a mold cavity with correspondingreceiving surfaces indicated according to one exemplary embodiment.

FIGS. 10 a-c are perspective views of the application of coveringmaterial to a mold cavity according to one exemplary embodiment.

FIG. 11 is a perspective view of a spray apparatus according to oneexemplary embodiment.

DETAILED DESCRIPTION

According to an exemplary embodiment, a vehicle component assembly(e.g., a vehicle seat assembly 100) is provided that is adapted for usein any variety of applications for a vehicle 110 (e.g., automobile,plane, train). The vehicle seat assembly 100 may be provided inlocations throughout the vehicle other than the location shown inFIG. 1. The vehicle component assembly according to an exemplaryembodiment can include a vehicle component of one color and a coveringmaterial of another color that is colored to more closely match thesurrounding vehicle components. The covering material can be a nonionicpolymeric colorant covering material for spray application to thevehicle component or to the cavity of a mold configured to form thevehicle component.

FIGS. 2 and 3 show a mold cavity 120 that can be used to mold a foamvehicle component for a vehicle according to one exemplary embodiment.It will be understood that the following description can apply to moldcavities to create vehicle components for the interior or exterior of amotor vehicle. A foam vehicle component can have a bright tone relativeto the surroundings components of the vehicle and in certain areas bemore noticeable than those surrounding components. To satisfy vehiclecraftsmanship concerns, it is desirable to conceal or camouflage thebright tone of the vehicle component so that it is hidden from vehicleusers or passengers. To do so, the covering material 16 can beselectively applied to the interior surface of the mold cavity 120. FIG.2 shows the mold cavity 120 prior to application of the coveringmaterial 16, and FIG. 3 shows the mold cavity 120 after application ofthe covering material 16. After curing of the foam vehicle component inthe mold cavity 120, the covering material 16 can cover the otherwisebright exterior surface of the foam so that is more closely matches thetone of the surrounding components of the vehicle. Application of thecovering material 16 to the mold cavity 120 will be explained in moredetail in connection with FIGS. 8 a-d, 9 a-b, and 10 a-c.

In the embodiment of FIGS. 2 and 3, the mold cavity 120 can be markedwith instructional language such as “CLOTH” or “APPLY HERE.” A cloth orupholstery material may be fastened to the interior surface of the moldcavity, and, following curing of the foam vehicle component in the mold,the cloth may adhere to the foam to provide improved foam durability.The cloth material might not, however, cover the entire exterior surfaceof the foam, and so covering material 16 may be applied to the moldcavity in those areas that the cloth does not reach. In this manner,after curing, cloth partially covers the foam vehicle component, and thecovering material 16 may cover the remainder so that the otherwisebright tone of the foam is not visible. In an alternative embodiment,the cloth may be attached to the foam vehicle component after curing inthe mold cavity 120.

Vehicle component 10 may be covered with a covering material 16 thatcamouflages the vehicle component as shown in FIGS. 4-7. The coveringmaterial 16 is an opaque material that at least partially covers theexterior of vehicle component 10. In one exemplary embodiment, thevehicle component 10 is composed of a foam member. Upon bonding orreacting with the foam vehicle component, the covering material 16adheres to the foam vehicle component and gives the appearance of atinted surface on the vehicle component.

The covering material 16 can include a black dye that bonds with thepolyurethane foam that is poured into a mold (e.g., the mold cavity ofFIG. 2-3). The polyurethane foam can fully react with dye in thecovering material upon solidification such that the covering materialdoes not disperse or rub off on other surfaces upon contact. Alsoincluded in the covering material mixture are deionized water and asilicone dispersing (or mixing) agent.

A process of making the covering material includes providing a blackopaque dye material, adding a deionized water solution to a siliconematerial, mixing the silicone material, water-based solution and opaquedye in a blend tank, and heating the material to a predeterminedtemperature. The mixing may be performed in an industrial mixing tankconfigured to blend the water, dye and silicone together. The tank mayalso include a heating unit. In one exemplary embodiment, the materialis heated to a temperature between 100 and 120 degrees Fahrenheit. Inanother exemplary embodiment, the covering material is heated between 80and 180 degrees Fahrenheit. The length of time the mixture is heated isalso variable. In one embodiment, the covering material is heated anywhere from 3 to 60 minutes.

The ratio of silicone to water to dye may change according to thespecified application. In one exemplary embodiment, the coveringmaterial consists of an at least 20% water-based solution. However, inanother exemplary embodiment, the amount of water-based solution in thecovering material may be altered to increase the viscosity of thecovering material according to different vehicle components havingdifferent surface characteristics. For example, a vehicle componentcomposed of a polymeric material requires a more viscous coveringmaterial than a vehicle component composed of a metallic material.Accordingly, the covering material can have different materialcharacteristics to accommodate the surface texture of the receivingsurface on the vehicle component. The embodiment of FIG. 7 showscovering material 16A and 16B of different levels of viscosity appliedto a metallic receiving surface. The covering material 16A demonstratesan appropriate range of viscosity for application to a metallicreceiving surface. The viscosity of the covering material 16B is outsideof the appropriate range of viscosity for a metallic surface. Thecovering material 16B includes too much water. The variation inviscosity of the covering material is represented by different gradientsor patterns as shown in FIG. 7.

The cover weight of the covering material may also change according tothe specified application. The desirable cover weight is greater forsome vehicle components than others. The cover weight for the coveringmaterial in one exemplary embodiment is between 5 and 15 grams forapplication to a foam seat member. In one exemplary embodiment, themixture contains between 0.001 and 75% dye depending upon the overallcoverage requirements.

In another exemplary embodiment, the covering material consists of atleast 0.001% dye. The dye is opaque and in one exemplary embodimentconfigured to match a predetermined color scheme of the vehicleinterior. For example, where adjacent components are of a darker hue,such as black or gray, the dye color may be black or charcoal so thatthe covered vehicle component compliments the color scheme of thevehicle interior. In the illustrated embodiments of FIGS. 4-6, thevehicle component 10 is a foam insert having a yellow tone. The vehiclecomponent is covered with a covering material having a black tone on atleast one surface after emulsifying in the mold cavity. Several shadesof black may be utilized with the covering material such as REACTINT®products Black 1852, Black 2151, Black 2256, Black X95AB or Black X77.

A process for improving vehicle seat craftsmanship by camouflaging areceiving surface on a vehicle component, the camouflaging therebyconcealing the receiving surface of the vehicle component fromobservation, is also provided. The process includes designating areceiving surface area on the vehicle component and providing a coveringmaterial having an opaque characteristic. The covering material includesdeionized water, an opaque dye, and silicone material. The processfurther includes spraying the covering material in a in a mold cavityaccording to a surface of the mold cavity which corresponds to thedesignated receiving surface area on the vehicle component until thecovering material completely covers a designated receiving surface areadefined on the mold cavity. The vehicle component is a foam memberconstructed from polyurethane poured into the mold cavity. Bydesignating the receiving surface, the amount of covering material isconserved and is applied only to the needed areas. The designated areais not limited to forming and covering any one of six sides as shown inFIGS. 5-6. For example, the designated area may also form the topsurface of a complex component as shown in FIG. 4 or a certain portionof a surface of the vehicle component as shown in FIG. 2.

The covering material 16 can be configured for spray application to themold cavity of the vehicle component 10. The application of the coveringmaterial can be with a standard fixed adjustable spray apparatus withpneumatic controls. In one exemplary embodiment, a plurality of spraynozzles are incorporated on the assembly line to enable the water in thecovering material to dry off faster so as to not create any surfacedamage. The spray nozzles may be coupled to a controller as a unit orindependently. In one exemplary embodiment, the covering material isapplied to the vehicle component at a pressure between 15 and 60 psi.

In exemplary embodiment, a process for improving vehicle seatcraftsmanship by camouflaging a plurality of receiving surfaces on avehicle component, the camouflaging thereby concealing the plurality ofreceiving surfaces on the vehicle component from observation, isprovided. The process includes designating the plurality of receivingsurfaces on the vehicle component and providing a covering materialhaving an opaque characteristic. The covering material includesdeionized water, an opaque dye, and silicone material. The processfurther includes providing a mold cavity, the mold cavity defining aplurality of corresponding receiving surfaces, each correspondingreceiving surface assigned to one of the plurality of receiving surfaceson the vehicle component; providing a spray apparatus; applying thecovering material to the corresponding receiving surfaces of the moldcavity; and pouring a polyurethane mixture into the mold cavity forsolidification. In one embodiment, the covering material is applied viaa spray apparatus 20 as shown in FIGS. 8 a-d. The spray apparatus 20includes a plurality of spray nozzles (or “guns”)—22, 24, 26, and28—configured to cover a corresponding receiving surface in the moldcavity (120, 30, 32, 34 and/or 36 as shown in FIGS. 2-3, 8 b, 8 d and 9a-b, respectively). The corresponding receiving surfaces are assigned toone of the plurality of receiving surfaces on the vehicle component. Thecorresponding receiving surfaces (“RS”) may be assigned indicators. Forexample, the corresponding receiving surface labeled “7” in FIG. 9 a isassigned to a receiving surface on the bottom perimeter of the vehiclecomponent.

Where the mold cavity includes a complex surface—e.g., 32 as shown inFIG. 8 d—the spray apparatus 20 is configured to include at least oneadditional nozzle 28 extendable to a position farther outward from theremaining spray nozzles 22, 24 and 26, thus enabling the extendablenozzle 28 to reach intricate position of the mold cavities (e.g., 32).The mold cavities 34 and 36 can define a plurality of receiving areas asshown in FIGS. 9 a-9 b which correspond to the shape of the vehiclecomponent 10. The mold cavity 34, as shown in FIG. 9 a, is a schematicrepresentation of a mold cavity for an individual passenger seat. Themold cavity 36, as shown in FIG. 9 b, is a schematic representation of amold cavity for a multiple passenger seat such as a seat bench or row.The spray apparatus 20 is configured to spray any number of theindicated receiving surfaces for coverage.

In one exemplary embodiment, a control module 40 (or panel), such asshown in FIG. 11, is coupled to the spray apparatus 20 to govern theapplication of the covering material to the corresponding areas on themold cavity. The spray apparatus 20 and/or mold cavity 34 are configuredto move with respect to each other as shown in FIGS. 10 a-c. Thedirection of movement “X” of the mold cavity 34 with respect to thespray apparatus 20 is shown in the exemplary illustrated embodiment. Thecontrol panel 40 also governs the pressure at which the coveringmaterial is applied to the mold cavity as provided by a pump 42 (orpneumatic control) as shown in FIG. 11. The covering material is fedfrom a tank 44 and into the spray apparatus 20 via the pump 42. The pump42 may be a high pressure low volume (HVLP) pump or other comparablepneumatic device known to persons of ordinary skill in the art. In oneexemplary embodiment, the control panel 40 and covering material areconfigured to apply the covering material at a rate of 0.8 seconds pervehicle component. In another embodiment, the control panel 40 isconfigured to apply the covering material from 0.1 to 1.5 seconds pervehicle component.

It will be understood that the vehicle component may be any number ofdifferent components such as foam cushion (or insulation) pieces,cavities defined by a plurality of other vehicle components, metallic orpolymeric surfaces, internal shafts, bonding materials, electronicwiring, fasters, and the like.

It should be understood that the construction and arrangement of theelements of the covering material and vehicle component in the exemplaryembodiments are illustrative only. Although several embodiments of thecovering material and vehicle component have been described in detail inthis disclosure, many modifications are possible (e.g., variations insize, dimensions, structures, shapes and proportions of the variouselements, values of parameters, mounting arrangements, use of materials,colors, orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited in the claims.For example, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of the elements may be reversedor otherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. Accordingly, all such modificationsare intended to be included within the scope of the present invention asdefined in the appended claims. Unless specifically otherwise noted, theclaims reciting a single particular element also encompass a pluralityof such particular elements. The order or sequence of any process ormethod steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and/oromissions may be made in the design, operating conditions andarrangement of the preferred and other exemplary embodiments withoutdeparting from the spirit of the present invention as expressed in theappended claims.

1. A process for improving vehicle seat craftsmanship by camouflaging areceiving surface on a vehicle component, the camouflaging therebyconcealing the receiving surface of the vehicle component, the processcomprising: designating a receiving surface area on the vehiclecomponent; providing a covering material having an opaquecharacteristic, wherein the covering material includes deionized water,an opaque dye, and silicone material; and spraying the covering materialin a mold cavity at a surface of the mold cavity corresponding to thedesignated receiving surface area on the vehicle component until thecovering material completely covers the surface defined on the moldcavity.
 2. The process of claim 1 wherein the vehicle component is afoam member constructed from a polyurethane mixture.
 3. The process ofclaim 2, further comprising: pouring the polyurethane mixture into themold cavity for solidification
 4. The process of claim 3 wherein thepolyurethane fully reacts with the dye during solidification therebypreventing the covering material from moving upon contact.
 5. Theprocess of claim 1, further comprising: calibrating the providedcovering material so that a water level of the covering materialcorresponds to the predetermined viscosity requirements for thedesignated receiving surface.
 6. The process of claim 1 wherein thespraying of the covering material on the designated surface is conductedat a pressure level between 5 and 100 psi. 7-17. (canceled)
 18. Aprocess for improving vehicle seat craftsmanship by camouflaging aplurality of receiving surfaces on a vehicle component, the camouflagingthereby concealing the plurality of receiving surfaces on the vehiclecomponent from observation, the process comprising: designating theplurality of receiving surfaces on the vehicle component; providing acovering material having an opaque characteristic; providing a moldcavity, the mold cavity defining a plurality of corresponding receivingsurfaces each corresponding receiving surface assigned to one of theplurality of receiving surfaces on the vehicle component; providing aspray apparatus; applying the covering material to the correspondingreceiving surfaces of the mold cavity; and pouring a polyurethanemixture into the mold cavity for solidification.
 19. The process ofclaim 18 wherein the covering material includes deionized water, anopaque dye, and silicone material.
 20. The process of claim 18 whereinthe vehicle component is a foam member. 21-23. (canceled)